IMPROVED WIRE ROPE LUBRICATOR DESIGN FOR A MINE

PRESENTED BY,

GAUTHAM KRISHNA S R
211218007
INDUSTRIAL SAFETY ENGINEERING
INTRODUCTION
• Wire ropes are used in mines for transmitting mechanical
power in mine hoists and cranes.
• Mine hoists are the fundamental mode of transport of workers
and goods into and out of the mine shafts.
• A wire rope without proper lubrication also causes wearing of
the sheaves, this would require re-grooving and replacement
with time costing a mining company thousands of rupees in
addition to down time during replacement.
OBJECTIVE
• The main objective of this study is to come up with a more
efficient method of lubricating wire ropes as well as reducing
the cost of wire rope cleaning and maintenance in a more
sustainable, and economic manner.
 WIRE ROPE
• Wire rope is a type of rope which consists of several strands of
metal wire laid (or 'twisted') into a helix.
• Wire rope systems are used as a means of transmitting
mechanical power.
• Stranded ropes are manufactured in 3 operations:
1. Manufacture of the core (center)
2. Spinning the wires into strands
3. Laying the strands to form the rope
 IMPORTANCE OF LUBRICATION
• During operation the strands that make up a wire rope are
under constant stress and strain.
• The strands constantly rub against one another causing
friction.
• The friction cause strands to wear.
• The friction heat causes oxidation resulting in high internal core
temperatures which in turn accelerates rusting and causes
premature rope failure.
EXISTING METHODS FOR LUBRICATION
• Grease drop lubricator

• The lubricator is only usable on sheaves hence if the installed

sheaves have no enough space to place it, adjustments have to
be made
• The design concept has a high risk of burning the operator
when they come into contact with the device while still hot.
EXISTING METHODS FOR LUBRICATION
• Dipping lubricator

• The device has to be very large as the rollers have to be big

enough to reduce fatigue in the rope due to bending over the
rollers
• Due to the high tension and fluctuating loads in the roller shafts
as the rope moves around the rollers, there is high risk of
failure on the shafts
PROPOSED DESIGN
DESIGN OF LUBRICATING COLLAR
FINISHED WIRE ROPE LUBRICATOR
 BENEFITS OF NEW DESIGN
• Good wire rope core lubricant penetration
• Reduce lubrication time
• Reduce reported wire rope related down time by 80%
• Reduce wire rope lubricating labour input hours by at least
50%.
• Portable for varying rope orientations
• Life span of at least 10 years
• Simple parts and easy to maintain
• Maximum weight of 25 kg
• Lubricant leak proof
 CONCLUSION
• The new design is a more efficient method of lubricating wire
ropes as well as reducing the cost of wire rope cleaning and
maintenance in a more sustainable, and economic manner.
• The device could achieve the required key design objectives of
lubricant penetration and time saving
 REFERENCES
• Journal by, Charles Mbohwa on "Improved Wire Rope
Lubricator Design for a Mine".
• American Iron and Steel Institute, Wire Rope User’s Manual,
Second Edition. p. 5-17, 67-68, 1985.
• Brewer A, Effective Lubrication, p. 236-242, 1974.
THANK YOU